System, method and apparatus for producing fire rated doors

A fire rated door comprising:

• a first routable door-sized panel;
• a second routable door-sized panel;
• two longitudinal interior channels formed by opposing longitudinal interior channels cut within the back of each door-sized panel;
• a large interior channel cut into the back of the first routable door-sized panel and/or the back of the second routable door-sized panel between the two longitudinal interior channels;
• a spline disposed within each formed longitudinal interior channel;
• a perimeter channel cut in each side of the door;
• an intumescent banding material disposed within each perimeter channel;
• an exterior banding disposed within each perimeter channel to conceal the intumescent banding material;
• one or more protective layers disposed within the large interior channel;
• wherein the back of the first routable door-sized panel, the back of the second routable door-sized panel and the one or more protective layers are attached to one another using an adhesive;
• a data device containing production data embedded within the door;
• and
• wherein the fire rating for the door is achieved by (a) the intumescent banding material and (b) one or more of the following (i) the adhesive is fire resistant, (ii) the one or more protective layers and (iii) the first routable door-sized panel and the second routable door-sized panel contain an intumescent or fire resistant material, or are coated with the intumescent or fire resistant material.

A fire rated door comprising:

• one or more protective layers disposed within a large interior channel cut into a back of a first routable medium density fiberboard door-sized panel and/or a back of a second routable medium density fiberboard door-sized panel, wherein the protective layers are coated with an intumescent material;
• two longitudinal interior channels formed by opposing longitudinal interior channels cut within the back of each door-sized panel;
• a spline disposed within each formed interior channel wherein each spline is coated with the intumescent material;
• a perimeter channel cut in each side of the door;
• an intumescent banding material disposed within each perimeter channel;
• an exterior banding disposed within each perimeter channel to conceal the intumescent banding material;
• wherein the back of the first routable door-sized panel, the back of the second routable door-sized panel and the one or more protective layers are attached to one another using an adhesive;
• and
• wherein the fire rating for the door is achieved by (a) the intumescent banding material and (b) the intumescent material coating the protective layers.

A fire rated door comprising:

• a first routable door-sized panel;
• a second routable door-sized panel;
• wherein a back of the first routable door-sized panel is attached directly to a back of the second routable door-sized panel using a fire resistant adhesive;
• two longitudinal interior channels formed by opposing longitudinal interior channels cut within the back of each door-sized panel;
• a spline disposed within each formed longitudinal interior channel;
• and
• wherein the fire rating for the door is achieved by the fire resistant adhesive without a mineral core disposed between the first routable door-sized panel and the second routable door-sized panel.